Tommy Docks TD-50400 Installation guide

Brand: Tommy Docks

Model: TD-50400

Type: Installation guide

Aluminum Dock Frame

Assembly Instructions

Tommy Docks

4003 Dixie Ave, Wausau, WI 54401

Phone : 715-842-3804

Toll Free : 866-675-1880

Fax : 715-842-3420

www.tommydocks.com

Power Drill

Tools

3/8” Box

End Wrench

5/16” Driver Bit #2 Phillips Bit Hex Bit

Self Tapping Screw

Qty 2

Stainless Steel

Hex Head Bolt

Qty 20

Stainless Steel

Tapered Head Screw

Qty 20

Stainless Steel

Nylon Locknut

Qty 40

Hardware

Aluminum Dock Kit

Components

48” End Rail

Qty 2

Side Rail

(96” of 120”)

Qty 2

Center I-Beam

(96” or 120”)

Qty 1

23 ⁄” Intermediate

Crossmember

Qty 2

Start by sliding the two (2) Side Rails into the End Rail (1a). The End Rail ﬁts in between the ﬂanges

on the Side Rail (1b).

Insert the Tappered Head Stainless Steel Screws at the corner (2 screws per corner) (2a). Hand

tighten the Stainless Steel Locknuts to all (4) corner screws at the top side of the frame (2b).

Flange

4x 4x

Stainless Steel

Tapered Head Screw

Stainless Steel

Locknut

Side Rail

End Rail

Side Rail

Flange of Side Rail

Insert the center I-Beam into the End Rail as shown (3a). Make sure notch in I-Beam engages Top

Flange of Side Rail (3b). The top ﬂange of the I-Beam goes on top of the End Rail Flange and the

Bottom Flange of the I-Beam sits on top of the Bottom Flange of Side Rail (3c). Insert the screws

and locknuts (3d) and hand tighten (3e).

Center

I-Beam

End Rail

Center

I-Beam

Bottom Flange

of I-Beam

Top Flange

of I-Beam

Top Flange

of Side Rail

Bottom Flange

of End Rail

Top Flange

of End Rail

End Rail

Notch

2x 2x

Install one Intermediate Crossmember I-Beam into the Side Rail (4a). Notice that the Intermediate

Crossmember ﬁts in between the ﬂanges on the Side Rails (4b) but not where it attaches to the

center I-Beam (4c). Attach with the screws and locknuts (4d) and hand tighten (4e).

Intermediate

Crossmember

I-Beam

Side Rail

Center

I-Beam

Intermediate

Crossmember

I-Beam

Center

I-Beam

Bottom Flange

of I-Beam

Top Flange

of I-Beam

2x 2x

Notice that the bottom ﬂange of the Intermediate Crossmember I-Beam ﬁts underneath the bottom

ﬂange of the center I-Beam (5a). Insert the screws and lock nuts (5b) and hand tighten (5c). Attach

the second Crossmember in the same manner as the ﬁrst, but do not install the screws into this side

rail yet.

2x 2x

Center

I-Beam

Bottom Flange of

Center I-Beam

Bottom Flange of

Intermediate

Crossmember

I-Beam

You now have all the frame components attached to the frame except the last End Rail. Make sure

all of the connections are ﬁtted tightly and tighten all of the screws you have installed so far on the

top side of the frame. Use the Hex Bit to fully tighten the Stainless Steel Tapered Head Screw while

holding in place the Stainless Steel Nylon Locknut with a 3/8” Box End Wrench.

This illustration shows the remaining connection of the Crossmember

into the Side Rail that remains unattached. The purpose for this is to

allow room to slide individual boards into place in the forward section

of the frame. (If you are planning on making removable drop in deck

panels for the frame you can disregard this step and install the screws

and tighten this connection to the Side Rail.)

Stainless Steel

Tapered Head Screw

Stainless Steel

Nylon Locknut

3/8” Box

End Wrench

Hex Bit

NOTE: When assembling the frame

components, if you encounter holes that do

not line up exactly, it is acceptable to use

a drill to ream out the holes slightly for the

fasteners to ﬁt appropriately.

This illustration shows the installation of individual deck boards into the ﬁrst half of the frame (7a).

(Disregard this step and the next step if you will be making removable deck panels.) Once you are at

the halfway point, install and tighten the screws and locknuts that attach the remaining Intermediate

Crossmember (7b). Use the Hex Bit to fully tighten the Stainless Steel Tapered Head Screw while

holding in place the Stainless Steel Nylon Locknut with a 3/8” Box End Wrench.

NOTE: When assembling the frame components, if you encounter holes that do not line up exactly, it

is acceptable to use a drill to ream out the holes slightly for the fasteners to ﬁt appropriately.

2x 2x

Stainless Steel

Tapered Head Screw

Stainless Steel

Nylon Locknut

3/8” Box

End Wrench

Hex Bit

Install the remaining deck boards into the frame.

Fit one end of the remaining End Rail into the Side Rail (9a). The End Rail ﬁts in between the ﬂanges

on the Side Rail (9b).

End Rail

Side Rail

Flange of Side Rail

Insert two (2) Truss Head Stainless Steel Screws at the corner (10a) and hand tighten (10b).Insert two (2) Truss Head Stainless Steel Screws at the corner (10a) and hand tighten (10b).

Make sure the top ﬂange of the I-Beam goes on top of the End Rail and the bottom ﬂange of the

I-Beam sits on top of the bottom ﬂange of End Rail(11a). Insert the screws and locknuts (11b) and

hand tighten (11c).

2x 2x

Bottom Flange

of I-Beam

Top Flange

of I-Beam

Bottom Flange

of End Rail

Top Flange

of End Rail

11a

11b

11c

2x 2x

Truss Head Stainless

Steel Screw

Stainless Steel

Locknut

10b

10a

Use the Hex Bit to fully tighten the Stainless Steel Tapered Head Screw while holding in place the

Stainless Steel Nylon Locknut with a 3/8” Box End Wrench.

NOTE: When assembling the frame components, if you encounter holes that do not line up exactly, it

is acceptable to use a drill to ream out the holes slightly for the fasteners to ﬁt appropriately.

Use the Hex Bit to fully tighten the Stainless Steel Tapered Head Screw while holding in place the

Stainless Steel Nylon Locknut with a 3/8” Box End Wrench.

NOTE: When assembling the frame components, if you encounter holes that do not line up exactly, it

is acceptable to use a drill to ream out the holes slightly for the fasteners to ﬁt appropriately.

Hex

Bit

Stainless Steel

Tapered Head Screw

3/8” Box

End Wrench

Stainless Steel

Nylon Locknut

3/8” Box

End Wrench

Hex

Bit

Stainless Steel

Nylon Locknut

Stainless Steel

Tapered Head Screw

Slide the last board into the frame and you will be able to ﬂex the remaining corner connection to

snap in the last deck board (14a). You may now push the remaining corner together (14b).

The ﬁnal top of the frame corner connection is made by installing the (2) Self Tapping Screws

provided (15a). Fit corner together tightly and tighten using 5/16” Driver Bit (15b).

14b

14a

15a 15b

Self

Tapping

Screw

5/16”

Driver Bit

NOTE: When assembling the frame

components, if you encounter holes that

do not line up exactly, it is acceptable to

use a drill to ream out the holes slightly

for the fasteners to ﬁt appropriately.

Flip the frame over to install the remainder of the fasteners into the frame. Where indicated install

Stainless Steel Hex Head Bolt and Stainless Steel Nylon Locknut (16a). Use the 5/16” Driver Bit to

fully tighten the Stainless Steel Hex Head Bolt while holding in place the Stainless Steel Nylon

Locknut with a 3/8” Box End Wrench (16b).

NOTE: When assembling the frame components, if you encounter holes that do not line up exactly, it

is acceptable to use a drill to ream out the holes slightly for the fasteners to ﬁt appropriately.

20x 20x

Hex

Bit

5/16” Driver Bit

3/8” Box

End Wrench

Stainless Steel

Hex Head Bolt

Stainless Steel

Hex Head Bolt

Stainless Steel

Hex Head Bolt

Stainless Steel

Nylon Locknut

16a

16b

Tommy Docks TD-50400 Installation guide

Tommy Docks TD-50400 Installation guide

Tommy Docks TD-50400 Installation guide

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